Mitsubishi 380 Sequent 56 Injection

Mitsubishi 380 Sequent 56 Injection
Aftermarket System
Installation Instructions
KIT PART NUMBER:ZIMI380AB01

FITTING INSTRUCTION REVISION 1
rd
Date: 23 May 2007
Page 1 of 36
Mitz_380_S56 Install Process_R2.doc
TABLE OF CONTENTS
LPG Engine Check ........................................................................................................................................3
Safety .............................................................................................................................................................3
Introduction....................................................................................................................................................4
Tools Required...............................................................................................................................................4
INSTALLATION ..........................................................................................................................................5
Vehicle preparation – Engine Bay .............................................................................................................5
Inlet Manifold ............................................................................................................................................6
Manifold Nozzles.......................................................................................................................................9
Manifold Nozzle Location.......................................................................................................................10
Manifold Nozzle Orientation ...................................................................................................................10
MAP Port .................................................................................................................................................11
Injector Nozzle Hoses..............................................................................................................................11
Bulkhead Wiring Hole.............................................................................................................................12
ECU / Regulator Assembly .....................................................................................................................12
Vapour Hose Filter Assembly .................................................................................................................14
Coolant Hoses..........................................................................................................................................14
Wiring Harness – Engine Bay .................................................................................................................15
Re-Install Inlet manifold..........................................................................................................................17
Terminal Removal ...................................................................................................................................18
CKP Sensor..............................................................................................................................................18
Wiring - Injectors 2, 4 & 6.......................................................................................................................18
Injector Rail Mounting ............................................................................................................................19
Wiring – Interior Preparation...................................................................................................................21
Switch Mounting .....................................................................................................................................23
Cylinder Mounting Holes ........................................................................................................................26
Floor Flange.............................................................................................................................................27
Filler Valve ..............................................................................................................................................28
Cylinder Mounting...................................................................................................................................29
Filler Line ................................................................................................................................................30
Re-Installing Engine Bay.........................................................................................................................32
Re-Installing Throttle Body .....................................................................................................................32
Compliance Plates and Labels .................................................................................................................33
Leak Testing ............................................................................................................................................34
Post Installation Check ............................................................................................................................34
Wiring Drawings .....................................................................................................................................35
Page 2 of 36
LPG Engine Check
CAUTION: Ensure the vehicle is fitted with an
LPG compatible engine. LPG engines have Three
(3) countersunk drilled holes on the engine head,
forward face, central location. Ref Figure 1
DO NOT FIT THIS LPG SYSTEM TO THE

VEHICLE IF THE THREE COUNTERSINK
DRILLED HOLES (3) ARE NOT PRESENT OR
THERE IS ANY DOUBT ABOUT THE
ENGINES COMPATIBILITY
Figure 1
Safety
• Follow all ADR and AS/NZS 1425 requirements when fitting this kit.
• The installation must comply with Australian standard AS 1425.
• NOTE: It is the installers responsibility to ensure that all Clauses of AS 1425 are met in full,
together with any other applicable State or Federal legislative requirements for a given vehicle
installation.
• Caution This symbol, indicates precautions that must be observed to prevent injury or
damage.
• Follow all standard workshop and occupational health and safety practices during the installation
process.
• Safety glasses and hearing protection must be used.
• General Information
• Before beginning the installation process read through these instructions thoroughly.
Page 3 of 36
Introduction Tools Required
Follow the fitting sequence as described and at the Right angle power drill with swivel hose
completion of the installation complete the connection
checklist located at the end of these instructions. 50mm hole saw
29mm hole saw
Check and note any existing marks or damage to 25mm hole saw
the vehicle. 22mm hole saw
20mm hole saw
Use fender guards, seat covers and any other Centre punch
protection required to prevent damage to the Drill bits:- 3mm, 4mm, 5mm, 11mm
vehicle during the installation process. M6 spiral tap
Debur tool
Do not place bolts and parts on vehicle body. Paint marker
Sharp knife
Check that all parts listed are included in the kit Ruler / tape measure (mm)
and are not damaged. Sharp flat end probe (connector pin removal)
Spanners / sockets:- 10mm, 12mm
Ensure all torque settings are followed. Screw drivers:- flat blade, phillips head
Torque wrench
Ensure brake lines never touch any other Rivet gun
components. Loctite 222
Scissors
Safely store any removed parts and note related 3 X Guard covers,
fasteners for correct refitting. Telescopic magnet
2 X Heater hose clamping pliers
All removed parts and fasteners must be retained Digital Multi Meter
unless indicated in the instructions.
Ensure ‘E’ bolts – earth bolts are refitted in the

location they were removed from.
Replace any coolant that is lost during coolant hose

rework.
Ensure all removed parts are refitted correctly.

Thoroughly clean all swarf from components and
the vehicle.
Road test the vehicle and confirm correct operation

of all components.
Page 4 of 36
INSTALLATION
Vehicle preparation – Engine Bay

Open the bonnet and place fender protectors over the LHF &
RHF guards
Disconnect battery negative, body ground and positive

terminals. Refer figure 3.
Remove strut support brace if installed, 4 M8 nuts. Refer

figure 2
Remove battery clamp and cover.

Remove battery and plastic battery tray.
CAUTION: Battery is heavy and in an

awkward position.
Figure 2
Remove engine cover, 4 bolts. Check to ensure washer insert
remains in cover. Refer figure 2.
Figure 3
Remove connector from MAF, (Mass Airflow Sensor), unclip

MAF wiring retaining clip from air box outlet housing.
Remove engine breather from induction hose.
Remove induction hose and air box outlet assy. Refer figure
4.
Figure 4
Page 5 of 36
Inlet Manifold
Remove 3 bolts from engine harness plastic former.
One from above transmission, two from front of engine,

figure 5,6
Disconnect wiring connections from:

MAP sensor and unclip retainer on harness, figure 8
10 way rear bank wiring connector, figure 7
3 way CKP (Crankshaft Position) sensor connector,
2 way connector.
Unclip rear harness cable tie from rear of wiring bracket,

remove 2 bolts on wiring support bracket, figure 7
Figure 5
Figure 6
Figure 8
Figure 7
Page 6 of 36
Remove 2 rear inlet manifold support bolts, figure 9
Disconnect brake booster vacuum hose.
Figure 9
Remove wiring connector from ETB, (Electronic Throttle

Body), remove 4 bolts from ETB and remove, figure 11
Remove 1 manifold support bolt from under ETB opening

in manifold, figure 10
Figure 11
Figure 10
Remove 1 bolt from ground lead at rear of manifold, figure

12.
Remove canister purge hose, remove 1 bolt from canister

purge valve support bracket.
Figure 12
Page 7 of 36
Remove 7 bolts from intake manifold and carefully lift from
engine and place onto bench, figure 13.
CAUTION: take care not to damage any

gasket mounting surfaces.
Figure 13
Cover intake runners on engine with covered used manifold

gasket, place 2 M8 bolts loosely into outside 2 holes in
gasket to prevent foreign material entry into engine, figure
14.
Figure 14
Page 8 of 36
Manifold Nozzles
Carefully place manifold onto supporting surface and mark
position as per attached drawing, manifold nozzle location.
CAUTION: mark position of nozzles, re-

measure before centre punch manifold and drilling.
Drill 3mm pilot hole in manifold, ensure drill central and

parallel to intake runner – refer drawing on right.
Enlarge holes with 5mm drill.
MAP Port
Refer drawing MAP Port, measure 40mm from throttle body
gasket surface and up 23mm from casting seam. Centre
punch manifold and drill 3mm pilot hole, enlarge hole to
5mm.
Tap all 7 holes with M6 spiral tap. Debur all 7 holes with a
flat mill file.
Clean manifold with compressed air and ensure no swarf left

in manifold, rotate manifold in all directions when cleaning.
CAUTION: Use eye protection when cleaning

with compressed air.
Apply Loctite 222 to manifold nozzles and secure in

manifold with M6 nuts, ensure nozzles in correct orientation
as per attached drawing, manifold nozzle orientation.
Torque manifold nozzles to 3-4Nm.
CAUTION: Do not over tighten manifold

nozzles as they may break.
Figure 15
Page 9 of 36
Manifold Nozzle Location
Manifold Nozzle Orientation
Page 10 of 36
MAP Port
Injector Nozzle Hoses

Attach 4 x 120mm injector hoses to centre 4 manifold
nozzles with Clic clamps.
Attach 2 x 135mm injector hoses to outside 2 manifold

nozzles with Clic clamps.
Cover manifold to prevent foreign material entry –

refitting will occur later to make installation easier.
Page 11 of 36
Bulkhead Wiring Hole
Locate flat panel inboard of brake booster on bulkhead,
measure 50mm from lip on brake booster and up 45mm
from lower edge of flat panel, mark location of hole,
figure 16.
Check to ensure no loose wiring on inside of vehicle

and drill 3mm pilot hole.
Figure 16
Enlarge hole with 25mm hole saw, figure 17.
Debur hole.
CAUTION: take care not to damage

power steering pipe.
Figure 17
ECU / Regulator Assembly

Remove 2 bolts from OEM wiring holder at front of
battery tray, figure 18.
Figure 18
Page 12 of 36
Mount LPG ECU onto rear face of bracket using two
M6X25 bolts, two M6 flat washers and M6 flanged nuts,
figure 19.
Place the flat washers between the bracket and ECU

housing.
Torque bolts to 6 – 8Nm
Figure 19
Place bracket into position onto battery tray; ensure

locating hole for plastic battery tray is fully exposed, figure
20.
Refit 2 OEM harness wiring holder securing bolts and

torque to 6-8Nm
Figure 20
CAUTION: Battery positive cable may route

very close to ECU/Regulator bracket. Cover and
tape battery positive cable with split tubing if
necessary to ensure integrity, figure 21.
Figure 21
Mount regulator assy onto air box side of bracket using 3 x

M6X12mm bolts with spring washers, figure 22.
Align front edge of coolant outlet fittings with edge of

bracket.
Torque bolts to 6-8Nm.
Figure 22
Page 13 of 36
Vapour Hose Filter Assembly
Connect 90 degree hose from vapour filter onto vapour
outlet on regulator. Install Clic clamp, figure 23.
Route straight section of hose under OEM engine wiring

and around rear of OEM wiring plastic former, continue up
between plastic former and engine breather hose.
CAUTION: Ensure filter has clearance to

OEM wiring.
Figure 23
Remove 8mm nut from under OEM wiring support, attach

18mm insulated clamp and torque nut to 10 +-2Nm, figure
24.
Once installed, bend ‘P’ clamp upwards slightly to ensure

vapour hose away from body panel.
Figure 24
Coolant Hoses
Connect longer exposed coolant hose onto top water fitting
on regulator and shorter onto lower, secure with clamps,
figure 25.
Route coolant hose beside vapour hose under OEM engine

harness formed protector to thermostat housing.
Measure 60mm from bend on OEM heater supply hose

(hose identified with white marking), and mark location.
Clamp hose with heater hose clamping pliers either side of
mark, cut hose and remove 20mm from engine side of hose.
Insert brass tee and secure hose with spring clamps with 3/8
outlet towards engine, figure 26. Figure 25
Connect regulator lower hose to brass tee and secure with

clamp.
Measure 110mm from bend on heater return hose (red

marking) and mark location. Clamp hose with heater hose
clamping pliers and cut hose, remove 20mm from engine
side of hose and install brass tee, secure hose with spring
Page 14 of 36
clamps.
Connect regulator top hose to brass tee and secure with

clamp.
Figure 26
Wiring Harness – Engine Bay

Feed from front of vehicle, feed 56 pin LPG ECU
connector under OEM engine harness plastic former and
above LPG vapour hose and engine breather hose, figure
27.
Ensure LPG harness routes over petrol rail supply line.
Figure 27
Continue to feed wiring through opening until branch for

oxygen sensors and regulator temperature are
approximately 100mm past wiring plastic former.
Pull through opening, fuse, relay, diagnostic, switch and

cylinder wiring and rear bank oxygen sensor connectors,
shorter oxygen sensor branch with 2 x grey 4 way
connectors, figure 28.
Pull through opening regulator temperature connector,

black 2 way connector.
Continue to route 56 pin connector under canister purge

valve vacuum hose, over carbon canister and connect to Figure 28
ECU.
Page 15 of 36
Disconnect rear bank precat oxygen sensor, light grey
connector on top, figure 29.
Connect LPG harness into corresponding connectors.
Route branch for temperature sensor, 2 way black

connector, to regulator temperature sensor and connect.
Figure 29
Locate front bank precat oxygen sensor connector on

radiator side of cylinder head, light grey 4 way connector,
figure 30.
Route LPG oxygen sensor wiring under OEM wiring above

radiator hose.
NOTE: Routing LPG wiring above OEM wiring in this

location may cause it to foul on engine cover when refitted.
Unplug and connect corresponding LPG harness

connectors.
Figure 30
Mount fuse and relay to bracket with M6 x 12mm bolts and

flanged M6 nuts, figure 31.
Remove bolt from bulkhead lip, insert fuse / relay bracket

and refit bolt.
Torque fuse relay bolts to 6+-1Nm

Torque OEM bolt to 10 +-2Nm
Figure 31
Route switch and cylinder wiring over carbon canister and

heater hoses on bulkhead and feed through wiring transfer
hole, figure 32.
Apply G16 corrosion inhibitor to hole before placing

grommet into position.
Position grommet into hole in bulkhead, pull bulkhead

matting over grommet before locating grommet into
bulkhead to ensure grommet seals onto body.
TIP: A 90 Degree scribe can be used to lift bulkhead

matting over wiring grommet.
Figure 32
Page 16 of 36
Remove plastic nut from stud on bulkhead beside heater
hoses, install 10mm insulated clamp onto switch/cylinder
branch of wiring and install clamp onto stud on bulkhead
with M6 flanged nut, figure 33.
Torque nut to 4-5 Nm
Ensure wiring does not touch brake lines.
Figure 33
Re-Install Inlet manifold

Remove bolts and cover over lower inlet manifold blanking
gasket.
Refit manifold gasket and place manifold upper onto

engine. Insert front 7 bolts on manifold, 1 bolt at throttle
body opening and 2 support bolts at rear of manifold, figure
34.
Insert all bolts before tightening any bolts.
Torque 7 manifold bolts in sequence from centre to outside.
Torque 2 rear manifold support bolts and bolt under throttle

body opening.
Figure 34
Torque all M8 manifold bolts to 18 +-2Nm
Refit MAP sensor and secure with bolt.

Torque to 5 +-1Nm
Refit brake booster vacuum hose.
Refit wiring bracket with 2 M6 bolts, figure 35.

Torque to 11 +-1Nm
Refit harness securing clip into bracket and around MAP

Sensor wiring, reconnect MAP Sensor connector.
Re-connect OEM 2 way connector.
Connect LPG mating 10 way connectors into either side of

OEM 10 way connectors. Figure 35
Secure wiring connectors to ensure no rubbing on nearby

brackets.
Do not refit throttle body at this stage.
Page 17 of 36
Terminal Removal
Remove secondary locking clip. Insert terminal probe into
connector to lift terminal retainer, gently lift retainer, slide
terminal forward and remove from connector, figure 36.
NOTE: All terminals to be removed from connectors

require the same process.
CAUTION: Do not apply excessive force on

terminals to remove them, once free terminals
will come out of connector easily.
Figure 36
CKP Sensor
Locate OEM 3 way female connector at front of engine.
Remove white secondary locking clip, figure 37.
Remove GREEN/RED wire from OEM connector and

insert LPG harness GREY terminated fly lead.
Insert OEM GREEN/RED wire into 1 way connector

supplied in LPG harness accessory bag. Connect to
corresponding GREY wire 1 way connector on LPG
harness.
Figure 37
Wiring - Injectors 2, 4 & 6

Align LPG wiring harness across front of engine with
branch out petrol injector circuits aligning with petrol
injectors 2, 4 & 6, figure 38.
Secure main branch of wiring to OEM wiring with 3 evenly

spaced cable ties across front of intake manifold, figure 38.
All 3 Petrol injector connectors have the same colored

power wire – DO NOT REMOVE.
PROCESS, figure 39,40.

Remove Petrol ECU Ground Signal wire from all 3 front Figure 38
petrol injector connectors, insert terminated fly lead from
LPG wiring into petrol injector connector. Insert OEM
injector ground signal wire into supplied 1 way connector
and connect to corresponding connector on LPG harness.
Reconnect petrol injector connectors, once complete.
Page 18 of 36
PETROL INJECTOR COLOR CODES
Petrol Inj2, OEM wire - YELLOW/RED

Petrol Inj2, LPG harness, ECU side – BLACK/WHITE
Petrol Inj2, LPG harness, Injector side – Black
Petrol Inj4, OEM wire - GREY/RED

Petrol Inj4, LPG harness, ECU side – BLUE/WHITE
Petrol Inj4, LPG harness, Injector side – BLUE
Petrol Inj6, OEM wire – YELLOW/PURPLE

Petrol Inj6, LPG harness, ECU side – ORANGE/WHITE
Petrol Inj6, LPG harness, Injector side – ORANGE
Figure 39
Figure 40
Secure wiring harness on front of engine to ensure no

connectors or wiring could rub on any components.
Secure LPG harness under throttle body location to OEM

harness including oxygen sensor connector.
Secure with two cable ties, LPG harness to upper rear

support on wiring harness plastic former facing throttle
body opening, figure 41.
Figure 41
Injector Rail Mounting

Remove 3 front bank ignition coil securing bolts.
Connect injector rail to rail bracket with short end of

bracket towards injector rail vapour inlet. Secure with 2
M6 flanged nuts, figure 42.
Torque bolts to 8~10Nm.
Figure 42
Page 19 of 36
Secure injector rail into position with vapour inlet towards
transmission end.
Start outer bolts, then lift injector rail gently to allow access
to centre coil bolt. Figure 43.
Torque coil retaining bolts to 10 +-2Nm.
Figure 43
Connect vapour hose to injector rail with Clic clamp, figure

44.
NOTE: Ensure vapour hose near plastic former not kinked

and foam protective sleeve protruding past wiring harness
plastic former.
Figure 44
Connect all 6 injector feed hosed to injector rail, figure 45.
Torque hose fittings to 4Nm
NOTE: over tightening of injector hose fittings will cause

injector to rotate in injector rail.
Figure 45
Connect injector wiring to LPG injectors and

Pressure/Temperature sensor, figure 46.
NOTE: injector numbering is, No.1 injector driver’s side,

No. 6 injector passenger side.
Figure 46
Page 20 of 36
Before securing LPG injector harness connector into
position, ensure COT tubing extends past support bracket
for engine cover, figure 47.
Figure 47
Wiring – Interior Preparation

Install protective covers to seats and floor carpet.
Open console, grip console trim with both hands and gently
lift from RHF corner and then continue to lift trim up from
clips evenly, figure 48.
NOTE: some retaining clips may remain in console,

remove trims and refit onto console fascia trim.
Console trim has 8 white plastic clips, ensure all refitted to

console trim mounting legs.
Figure 48
Remove tissue cavity fascia trim; gently pull towards rear

of car, figure 49.
Unplug wiring to 12V accessory socket.
Figure 49
Page 21 of 36
Remove RH lower dash trim, remove 2 screws from bonnet
release cable, and remove 3 trim retaining screws across
lower edge. Figure 50.
Figure 50
Remove rear seat base. Lifting front edge will release

retaining clips.
NOTE: Take care not to damage paint on vehicle with

front support legs of rear seat base.
Remove LHF and LHR scuff trim, gently lift front of trim
to release clips. Lift rear of trim to release rear clips, figure
51.
Remove LHF kick trim.
Figure 51
Page 22 of 36
Switch Mounting
Remove LPG switch from switch housing.
Align switch housing on outside top edge of tissue cavity,

figure 52.
NOTE: align rear edge of switch housing approx 3mm

inside outside side edge of tissue cavity to ensure straight
switch mounting.
Mark position of 3 mounting holes. Drill holes with 5mm

drill.
NOTE: hold sound proof matting away from drill as it may

catch and rip. Figure 52
CAUTION: Ensure all your body parts are
clear when drilling holes.
Towards top rear edge of tissue cavity, behind where

switch will mount, drill 2 10mm holes, file out centre
between two holes to allow for switch connector to pass
through cavity, figure 53.
NOTE: cut sound matting slight to allow access, matting

will catch on drill if access not pulled back.
Mount switch housing onto top inside of tissue box and

secure into position with 3 x 5mm rivets.
Figure 53
Route interior wiring from transfer hole over ventilation

duct, secure wiring to HVAC motor wiring behind
ventilation duct, figure 54.
Continue cylinder wiring over rear edge of duct and down

behind carpet matting and across console to passenger foot
well.
Figure 54
Page 23 of 36
Pass switch wiring into tissue box cavity, pass switch
connector through rear opening of tissue box and through
switch housing, figure 55.
Reconnect 12V auxiliary wiring and refit tissue cavity into

position. Connect switch to LPG wiring and insert switch
into position.
Refit console upper fascia trim, figure 56.
Refit RH lower dash trim, 3 screws, and bonnet release, 2

screws.
Figure 55
Figure 56
Secure cylinder wiring to glove box hinge support panel

with cable ties in existing holes in panel, figure 57.
NOTE: Ensure wiring secured to upper edge of lip to avoid

dropping down to be visible.
Figure 57
Continue LPG wiring from LH kick trim area to follow

OEM wiring along LH sill trim to rear seat base area.
In LH Front sill area, lift weather seal from sill area, tuck
LPG wiring into OEM wiring clips, figure 58. Refit
weather seal.
Secure front section in kick trim area to OEM wiring with 1

cable tie.
Figure 58
Page 24 of 36
Secure LPG wiring to OEM wiring through LHR sill and
seat base area and into boot cavity with cable ties spaced at
approximately every 200mm, figure 59, 60.
Figure 59
Figure 60
Refit LHF kick trim.
Refit LH front and rear scuff trims.
Refit rear seat base.
Page 25 of 36
Cylinder Mounting Holes
Remove boot mat, spare wheel and LH side boot trim.
Position cylinder mounting template into boot cavity, push

forward until sitting against body panel, hold template
forward and push towards RH side of vehicle, figure 61.
Lift rear back seat trim at lower edge and ensure template
secure against forward and RH side edge of body panel,
figure 62.
Mark position of all 4 mounting holes of cylinder.
Centre punch all 4 mounting hole locations, drill all holes Figure 61
with 3mm pilot hole.
Figure 62
Place boot mat back into boot cavity and mark location of
all 4 mounting holes into boot mat, remove boot mat.
Place boot mat upside down on clean surface, place

cylinder template onto boot mat upside down and align
with marked holes in boot mat.
Mark location of areas to be cut in matting. Cut carpet

sections with sharp knife / industrial scissors. Cut out
section of matting reinforcement with air hack saw or
equivalent.
Enlarge forward 2 cylinder mounting holes with 20mm

hole saw. Debur and insert telescopic magnet into hole to
extract swarf and panel slugs from hole saw. Apply G16
corrosion inhibitor.
Enlarge rear 2 holes with 12mm drill, debur and apply G16
corrosion inhibitor.
Page 26 of 36
Floor Flange
Remove LHR wheel,
Remove LHR wheel house trim,
From inside LHR wheel arch, locate 2 body ribs in top of
fuel filler recess in body.
Directly in the centre of the two floor ribs and level with
the bottom edge of the short rib, centre punch and drill
3mm pilot hole, figure 63.
NOTE: location of floor flange hole important to

installation of pre-formed steel service line.
Figure 63
Locate floor rib forward of floor flange pilot hole, measure

up 20mm and draw line parallel to rib. Measure 80mm
from floor flange hole and centre punch, drill 3mm pilot
hole, figure 64.
Enlarge floor flange hole to 50mm.
Enlarge rear wiring hole to 22mm.
Debur both holes.
Refit LH boot trim and mark location of 50mm floor flange

hole, remove boot trim and cut out floor flange hole. Figure 64
Place floor flange in position with longer section of

chamfered outlet towards top, (Large AMR writing at
bottom), mark position of all 4 floor flange holes, figure 65.
Centre punch hole locations, drill with 3mm pilot drill,

enlarge holes to 5mm.
Debur holes and coat with G16 corrosion inhibitor.
Apply sealant to floor flange and position into position and

secure with 4 x 5mm rivets.
NOTE: may need to run 5mm drill through mounting holes

in floor flange to enable rivets to pass through. Figure 65
Refit boot LH side trim.
Page 27 of 36
Filler Valve
Remove protector fuel filler 3 x M8 bolts, figure 66.
Remove 2 bolts from petrol filler neck from floor cross
member,
Remove 3 bolts from top of filler neck and remove filler
neck assembly and lay into wheel arch cavity.
Figure 66
Cut out filler template from filler package, figure 67. Insert
into filler pocket aligning the mounting holes of the petrol
filler top right and lower. Tape template into position and
centre punch filler 28mm hole, figure 68.
Drill 3mm pilot hole and enlarge to 29mm, debur hole and
coat with G16 Corrosion inhibitor, figure 69.
Figure 67
Figure 68
Figure 69
Page 28 of 36
Place petrol filler neck into position and insert LH front
bolt into top of filler neck.
Refit bolts to lower support on petrol filler neck beside

LHF cylinder mounting.
Apply sealant to 29mm hole for filler valve and place filler
valve into position, insert M6 filler bolts, figure 70.
Tighten all filler bolts to 10 +-2Nm
Torque lower petrol filler bracket to 20 +-4Nm

Figure 70
Cylinder Mounting
Carefully unwrap cylinder, remove all components from
fitting kit.
Apply 2mm bead of Loctite 577 or Loxeal 58-11 to 90

degree brass fitting in LPG kit accessory bag, screw into
AFL fitting in cylinder, Torque to 12~16Nm then clock at
90 degrees towards service solenoid valve, figure 71.
Figure 71
Place cylinder carefully into position in boot cavity, taking

care to place cylinder to avoid scratching paint on boot
floor.
Lift rear edge of cylinder and place spacers into position

under rear mounting legs of cylinders, hole in spacer must
fit neatly around nutsert, figure 72.
Align rear cylinder holes with holes in vehicle body.
Raise vehicle on hoist.
Figure 72
Page 29 of 36
Place spring washer, flat washer and swaged bracket onto
110mm bolt, feed crush tube over bolt and insert through
holes in cross member and screw into cylinder front
mounting brackets, figure 73.
Place spring washer, flat washer and flat backing bar over
30mm bolt, insert bolts into rear cylinder mounting holes.
Torque rear two bolts, then front two.
Torque cylinder mounting bolts to 31 +-2 Nm.
Place vent hose onto floor flange, install floor flange end Figure 73
clamp with tightening screw at bottom and facing forward.
Place valve box clamp onto vent hose with tightening

screw towards top and facing forward. Connect vent hose
to valve box outlet.
Place clamps in orientation on vent hose to avoid clamp

tang protruding into main boot cavity, figure 74, 75.
Figure 75
Figure 74
Filler Line
Install filler line through vent hose with straight fitting to
be connected to AFL valve, figure 76.
Figure 76
Page 30 of 36
Connect filler line to LPG filler valve, secure filler line to
petrol filler with cable tie on petrol filler breather tube,
figure 77.
Torque filler flare nut at filler and cylinder to 28 +-4 Nm
NOTE: do not refit wheel house liner until system leak

check completed.
Figure 77
Mount front gas lock onto regulator bracket assembly with

straight fitting facing front of vehicle using M6 X 20mm
bolt and flanged M6 nut., figure 78.
NOTE: Do not tighten gas lock securing bolt until after

liquid pipe installed.
Connect front liquid pipe from regulator to gas lock.
Torque gas lock mounting bolt to 6-8 Nm
Torque service line flare fittings to 18 +-2 Nm.

Figure 78
From under vehicle, route front section of liquid line

following OEM brake fuel bundle, figure 79.
NOTE: Routing service line through front crossmember

area ensures clearance of service line.
Continue to route service line following petrol brake / fuel

bundle along vehicle body.
Figure 79
At rear of petrol tank, route inboard of chassis rail and

above rear suspension frame, follow petrol filler neck up to
floor flange. Figure 80.
LPG Harness wiring at Cylinder:

Green = Gas Lock Power
Green/Black = Gas Lock Ground
Black = Sender Ground
White/Black = Sender Signal
NOTE: Ensure clearance to all sections of steel service line

to body.
Figure 80
Page 31 of 36
Re-Installing Engine Bay
Refit carbon canister into bracket and connect vacuum
hoses.
Ensure canister purge solenoid hose is rearward and

towards battery of front liquid line, figure 81.
Refit battery tray, battery and battery cover. Connect

negative lead to body and negative terminal on battery.
Connect LPG ground lead to battery terminal.
Connect LPG positive, (RED) fly lead to positive battery

terminal, install terminal onto battery and check clearance
of lead on regulator bracket.
Figure 81
Body ground Torque 7~11Nm
Battery Terminal Torque 5 +-1Nm
Re-Installing Throttle Body

Refit throttle body with new gasket supplied in LPG kit.
Torque bolts to 10 +-2Nm
Connect wiring to throttle body, figure 82.
Figure 82
Refit canister purge bracket and connect canister purge

hose, figure 83.
Torque bolt to 11 +-2Nm.
Refit engine ground.

Torque to 7 ~ 11Nm
Figure 83
Page 32 of 36
Refit air box outlet housing, connect MAF sensor
connector and retaining clip in air box housing, figure84.
Refit induction hose and connect engine breather hose.
Figure 84
Refit rear boot matting.
Check cooling system level and top up with Mitsubishi

specified coolant as required.
Pressure test cooling system and check for leaks, repair as

required.
Compliance Plates and Labels

Connect LPG diagnostic connector to hole in side of fuse
relay bracket.
Complete all details on State Compliance plate and

securely attach to bulkhead to the left of OEM compliance
plates with adhesive, figure 85.
Figure 85
Attach system compliance plate to bulkhead on right of

OEM compliance plates, figure86.
Figure 86
Page 33 of 36
Leak Testing
Fill LPG cylinder with 5 liters of LPG. Check filler
assembly for any leaks & repair as required.
Refit LH Rear wheel house liner and LHR wheel.
Start vehicle and allow engine to reach operating

temperature.
Raise engine RPM and change to LPG operation. Turn

engine off and check all liquid and vapour LPG lines and
connections for leakage.
Restart engine, allow to change over to LPG, take note of

transition from petrol to LPG, ensure no misfire present.
Refit engine cover.
Fill remaining capacity of LPG cylinder and record on

installation checklist.
Road test vehicle and ensure vehicle operation on both

fuels.
Post Installation Check
Complete warranty card and send to IMPCO

Technologies P/L.
Page 34 of 36
Wiring Drawings
Page 35 of 36
Page 36 of 36

Mitsubishi 380 Sequent 56 Injection

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Mitsubishi 380 Sequent 56 Injection

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Mitsubishi 380 Sequent 56 Injection

KIT PART NUMBER:ZIMI380AB01

DO NOT FIT THIS LPG SYSTEM TO THE

Ensure ‘E’ bolts – earth bolts are refitted in the

Replace any coolant that is lost during coolant hose

Ensure all removed parts are refitted correctly.

Road test the vehicle and confirm correct operation

Vehicle preparation – Engine Bay

Disconnect battery negative, body ground and positive

Remove strut support brace if installed, 4 M8 nuts. Refer

Remove battery clamp and cover.

CAUTION: Battery is heavy and in an

Remove connector from MAF, (Mass Airflow Sensor), unclip

Remove engine breather from induction hose.

One from above transmission, two from front of engine,

Disconnect wiring connections from:

Unclip rear harness cable tie from rear of wiring bracket,

Disconnect brake booster vacuum hose.

Remove wiring connector from ETB, (Electronic Throttle

Remove 1 manifold support bolt from under ETB opening

Remove 1 bolt from ground lead at rear of manifold, figure

Remove canister purge hose, remove 1 bolt from canister

CAUTION: take care not to damage any

Cover intake runners on engine with covered used manifold

CAUTION: mark position of nozzles, re-

Drill 3mm pilot hole in manifold, ensure drill central and

Enlarge holes with 5mm drill.

Clean manifold with compressed air and ensure no swarf left

CAUTION: Use eye protection when cleaning

Apply Loctite 222 to manifold nozzles and secure in

Torque manifold nozzles to 3-4Nm.

CAUTION: Do not over tighten manifold

Manifold Nozzle Orientation

Injector Nozzle Hoses

Attach 2 x 135mm injector hoses to outside 2 manifold

Cover manifold to prevent foreign material entry –

Check to ensure no loose wiring on inside of vehicle

Enlarge hole with 25mm hole saw, figure 17.

CAUTION: take care not to damage

ECU / Regulator Assembly

Place the flat washers between the bracket and ECU

Torque bolts to 6 – 8Nm

Place bracket into position onto battery tray; ensure

Refit 2 OEM harness wiring holder securing bolts and

CAUTION: Battery positive cable may route

Mount regulator assy onto air box side of bracket using 3 x

Align front edge of coolant outlet fittings with edge of

Torque bolts to 6-8Nm.

Route straight section of hose under OEM engine wiring

CAUTION: Ensure filter has clearance to

Remove 8mm nut from under OEM wiring support, attach

Once installed, bend ‘P’ clamp upwards slightly to ensure

Route coolant hose beside vapour hose under OEM engine

Measure 60mm from bend on OEM heater supply hose

Connect regulator lower hose to brass tee and secure with

Measure 110mm from bend on heater return hose (red

Connect regulator top hose to brass tee and secure with

Wiring Harness – Engine Bay

Ensure LPG harness routes over petrol rail supply line.

Continue to feed wiring through opening until branch for

Pull through opening, fuse, relay, diagnostic, switch and

Pull through opening regulator temperature connector,

Continue to route 56 pin connector under canister purge

Connect LPG harness into corresponding connectors.